Front Axle Shaft Assembly/Disassembly
Drive axle with CV joint, servicingGrease (G6) for CV joints
When replacing boot -5- or -8-, grease joint again if necessary.
1. Circlip
Always replace
Remove and install with special tool VW161A (- Fig. 3) or commercially available circlip pliers, depending on version
2. Gasket
Replacing: remove protective backing and adhere to joint
3. Constant velocity (CV) joint, inner
Diameter: 100 mm
Replace complete unit only
Pressing off - Fig. 4
Pressing on - Fig. 5
4. Spring washer
Installation position - Fig. 6
5. Joint boot with cap
Check for cracks and abrasion
Drive off with mandrel
Before assembly onto CV joint, coat face with D3
6. Axle shaft (splined shaft)
Left- and right-side shafts have different lengths
7. Clamp
Always replace
Tightening - Fig. 1
8. Joint boot
Check for cracks and abrasion
Before tightening small clamp, ventilate briefly - Fig. 2
9. Clamp
Always replace
Tightening - Fig. 1
10. Spring washer
Installation position - Fig. 8
11. Spacer
Installation position - Fig. 8
12. Lock ring
Always replace
Installation position - Fig. 8
During assembly, install in groove on shaft (not visible with joint installed)
13. Constant velocity (CV) joint, outer
Diameter: 88 mm
Replace complete unit only
Pressing off - Fig. 7
Installing: drive on joint with soft-faced hammer until lock ring latches into ring groove of axle shaft
Fig. 3 Ventilating CV boot:
Attaching the boot to the outer body of the joint frequently requires compressing or squeezing the boot. This can leave too little air inside the boot, which may cause a crease to develop (arrow).
For this reason, after installing the boot, ventilate it briefly by letting some air in at the small diameter end to restore the correct shape.
Fig. 4 Pressing off inner CV joint:
While pressing off, support ball hub.
Fig. 5 Pressing on inner CV joint:
Press joint in to stop and install circlip.
Note: Chamfer on inner diameter of ball hub (splined) must face toward collar on axle shaft.
Clamp drive axle in vise with jaw covers.
Remove clamp.
Push back joint boot.
Thread in special tool 3207 (with M16 thread) until CV joint is pressed off axle shaft.
Fig. 6 Installation position of dished washer, spacer washer and circlip:
1. Lock ring
2. Spacer
3. Spring washer